STANDARD OPERATING PROCEDURE
Raw Milk Cheddar Production
FILE NAME: Location on your computer/company network
Authored by: Keeley O’Brien
Last Modified on: 08/01/2014
EFFECTIVE DATE: Date of Approval
APPROVED BY: ______
The following individual is responsible for implementation of this SSOP and has overall authority on-site:
Name: ______Title: ______
Date: ______
1.0 PURPOSE
To establish rigid procedures to be followed during the cheese making process for raw milk cheeses in the plant. A strict record of all proceedings shall be made so that food safety/quality issues might be addressed.
2.0 SCOPE
This SOP applies to the production of raw milk cheese produced at the plant and all employees that are involved in the production of this cheese.
3.0 SAFETY & ENVIRONMENTAL CONSIDERATIONS
When working around hot water, chemicals, and equipment with moving parts, always use care and follow instructions for use.
4.0 FREQUENCY
This SOP applies anytime raw milk or thermalized cheese is produced
5.0 RESPONSIBILTY
· TASK
Plant Staff, anyone using the plant for cheese production
· VERIFICATION
Plant Manager/PPS
· PAPERWORK REVIEW
As needed to address quality or safety concerns, by appropriate managers/regulatory officials
6.0 PROCEDURE ****NOTE***this procedure is for raw milk cheddar cheese. Cultures used, aging, and certain steps for other styles of cheese will differ, depending upon the cheese type.
6.1 Cheese making preparation
A. In a clean and properly sanitized vat, add raw milk volume. Take initial pH reading and record it.
B. Warm milk to 90.0°F while gently mixing.
6.2 Fermentation
A. Record lot numbers of cultures and calcium chloride on the make sheet (see Appendix A for make sheet).
B. Add culture(s) at the appropriate amounts. See make sheet for standards as mathematical calculations are required based on milk volume for all ingredients.
C. Stir vat for 5-10 minutes to ensure adequate and complete distribution of culture. Maintain heat on vat +/- 1°F during fermentation stage. Fermentation stage takes approximately 45-60 minutes.
D. pH measurements must be taken at the intervals specified in the make sheet and recorded to ensure the culture is functioning and there is an increase in acidity. Record this reading on the make sheet. Add calcium chloride. Calcium chloride is added at a rate of 96 ml/100 gallons of milk.
6.3 Coagulation
A. Record lot number of rennet/coagulant on the make sheet.
B. Upon attaining a pH of 6.57-6.61, add rennet (or coagulant of choice) to milk and stir for 1-2 minutes. Maintain temperature at 89-90°F (+/-1°F) to ensure rennet functions at the same level between production lots (enzymatic reactions are temperature sensitive). Rennet set takes 30-45 minutes with properly function enzyme. Determining when the curd is ready to cut must be determined and takes expertise and experience.
6.4 Cutting
A. Using a clean and sanitized cheese knife cut the curd first with the horizontal cheese knife the length of the vat.
B. Using a clean and sanitized cheese knife cut the curd next with the vertical cheese knife the length of the vat.
C. Finally, using the vertical knife, cut the curd across the vat. Ensure that all cheese has been cut and a uniform cube size throughout has been obtained. Take some cheese out and measure pH and record on make sheet.
6.5 Healing
A. Allow the curd to heal after cutting for approximately 5 minutes. This is done by not agitating or heating.
B. Allow the curd to heal for another 10 minutes, but at this time with very gentle stirring (lowest stir setting on the vat) to keep the curd from coagulating back together. Take a pH reading and record.
6.6 Cooking
A. Increase temperature gradually from the current temperature (should be 88-90°F range) to 94°F over 15 minutes with very gentle stirring.
B. Increase temperature gradually from 94°F to 102°F over 15 minutes, gradually increasing the rate of stirring during this time. Cheese should continue to be cooked and stirred at 102°F until a pH of 6.35.
6.7 Draining
A. Place a clean and sanitized drain strainer in vat to keep cheese in the vat. Open the drain and drain off whey. Pull cheese curd up against vat sides to help facilitate whey draining. Allow cheese to drain in a mat for 15 minutes. This also allows the curd mat to knit back together.
B. Cut mat into manageable pieces (5-10 lbs) for the cheddaring process. Take a pH reading and record.
6.8 Cheddaring
A. Cheddaring is a term that means flipping cheese curd mats to facilitate whey draining. The manageable curd mats as the cheddaring process goes on are stacked so that the added weight/pressure helps push out more whey. The pieces are cheddared every 15 minutes for as many times as it takes for the pH to drop to the 5.35-5.40 range.
6.9 Milling
A. After reaching a pH of 5.35-5.40, the cheddared pieces are milled using a clean and sanitized milling machine. CAUTION: Milling machine has moving parts and spinning blades!
6.10 Salting
A. Record lot number and manufacturer of salt on the make sheet.
B. Salt concentration must be calculated based on the volume of milk that you started with. Salt is added at a rate of 2.565 lbs/100 lbs of curd. Salt should be split into several applications to ensure proper distribution. For vats <100 gallons, 2 applications can be done, for >100 gallons,3- 4 applications should be made.
C. Add first salt application (~ ¼ of salt total) and mix thoroughly. Wait 5 minutes.
D. Add second salt application (~ ¼ of salt total) and mix thoroughly. Wait 5 minutes.
E. Add third salt application (~ ¼ of salt total) and mix thoroughly. Wait 5 minutes.
F. Add fourth salt application (~ ¼ of salt total) and mix thoroughly. Wait 5 minutes.
G. Take pH reading and record it on the make sheet. Molding should occur when the pH is at approximately 5.25.
6.11 Moulding
A. Thoroughly wash and sanitize hands. Place cheese into molds as required being careful not to contaminate the cheese in the process. Molds and any additional equipment that will come in contact with the cheese must be clean and sanitized.
B. On the make sheet in NOTES, RECORD how much cheese was made (IE: 5-20 lb blocks, 30-2 lb wheels, 6-5 lb bags of curd). This becomes important for traceability and recall situations, if ever required.
6.12 Pressing
A. Place moulds into the press at required pressure level. For example:
B. Initial pressure on the cheese should be set at 10 lbs.
C. After 1 hour, increase the pressure to 20 lbs.
D. After 1 more hour, increase the pressure to 30 lbs. Leave the cheese at room temperature in the press overnight.
6.13 Aging
A. Take cheese out of molds and place in aging room. Take pH reading and record it.
B. Age for approximately 2-3 days to dry.
B. Depending upon aging process, coat cheeses with wax, wrap in cheesecloth and seal with lard, or seal in vacuumpack bags.
C. Put cheese into aging room
D. Age for the appropriate amount of time, flipping the cheese for even aging every week.
E. Sample the cheese monthly after month #3 to ensure flavor profile/development is occurring.
F. Take pH reading at every sampling and record it. This will help to make a consistent product.
7.0 DOCUMENTATION
Cheese Make Sheet, Pasteurization Records, Lot Numbers for any products used during processing, Troubleshooting Guide.